Selective Build Strategy Modification for Additive Manufacturing

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Solution Overview

Problem

Current additive manufacturing techniques lack the ability to readily modify build strategy parameters for specific regions of an object, leading to potential issues such as increased surface roughness or altered material properties in sensitive areas, which cannot be easily controlled or customized.

Innovation Solution

A computerized method and system that allow users to manually select and modify build strategy parameters within specific regions of an object code, enabling customization of parameters like stitching region positions, sizes, and scan vector end gaps during the additive manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated build strategy parameters are used for the entire object, then productivity is improved, but manufacturing precision deteriorates in sensitive areas

Engineering Contradiction:

Improvebuild speedVSAvoidsurface finish

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The build strategy parameters are segmented by spatial location, allowing different parameters to be applied to different regions of the object. The system divides the build space into zones (e.g., sensitive areas vs. non-sensitive areas) and assigns appropriate parameters to each zone, enabling high-speed building in non-sensitive regions while maintaining high precision in sensitive regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements local quality by allowing build strategy parameters to vary locally across different regions of the object. Instead of applying uniform parameters globally, the system enables region-specific parameter customization (e.g., stitch region placement, scan vector settings) to optimize both surface finish and build speed for each local area.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If build strategy parameters are customized for specific regions, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvematerial propertiesVSAvoidparameter management

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system provides self-service capabilities through automated tools that assist users in defining and managing region-specific parameters. The software includes built-in functionality for automatically identifying sensitive areas, suggesting optimal parameter settings, and managing the complexity of regional parameter customization, thereby reducing the burden on users while maintaining precision.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If manual revision of object code is performed to control stitching regions, then manufacturing precision is improved, but loss of time increases

Engineering Contradiction:

Improvestitching region controlVSAvoidcode revision time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary actions by automatically configuring build strategy parameters and defining stitching region locations before the actual additive manufacturing process begins. The software pre-processes the object code to identify sensitive areas and assign appropriate parameters, eliminating the need for time-consuming manual revisions during or after the build process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual mechanical code revision with an automated software-based system. Instead of requiring users to manually edit object code to control stitching regions, the system uses automated algorithms to interpret the 3D model, identify sensitive areas, and generate the appropriate build strategy parameters, significantly reducing the time required for parameter configuration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables precise control over the additive manufacturing process, allowing for improved surface finish and material properties in sensitive areas, reducing labor-intensive revisions and enhancing the ability to customize build strategies for complex geometries.

Implementation Method 1

The melting may be performed by a high powered irradiation beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal

Methodology Applied

Scientific EffectLaser melting: Laser Beam Welding

Implementation Method 2

The irradiation beam moves in the X-Y direction, and has an intensity sufficient to fully weld (melt) the metal powder to form a solid metal

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS10471510B2Selective modification of build strategy parameter(s) for additive manufacturing

Publication Date: 2019.11.12 GE INFRASTRUCTURE TECH LLC

AI summary

A computerized method, system, program product and additive manufacturing (AM) system are disclosed. Embodiments provide for modifying object code representative of an object to be physically generated layer by layer by a computerized AM system using the object code. The computerized method may include providing an interface to allow a user to manually: select a region within the object in the object code, the object code including a plurality of pre-assigned build strategy parameters for the object that control operation of the computerized AM system, and selectively modify a build strategy parameter in the selected region in the object code to change an operation of the computerized AM system from the plurality of pre-assigned build strategy parameters during building of the object by the computerized AM system.